The Practical, Easy-to-Use Guide to Lean Sigma Problem-Solving
Lean Sigma delivers results if you use the right tools and techniques. In Lean Sigma: A Practitioner s Guide, Dr. Ian Wedgwood captures best-practice Lean Sigma experience from multiple projects and industries, helping any professional identify the solution that will work best and implement it.
Wedgwood s exclusive "project roadmaps" present the fastest, most effective route to solving a wide range of problems and explain why those solutions make sense. His "discovery roadmaps" help you identify potential Lean Sigma projects, even in processes where there are no obvious targets.
The heart of Lean Sigma is Wedgwood's 48 individual "tools roadmaps": step-by-step instructions revealing exactly how and when to use all these Lean Sigma tools...
5 Whys
5S
Affinity
ANOVA
Boxplots
Capability tools
Cause & effect matrices
Chi-Square
Control charts
Critical path analyses
Customer tools
Demand tools
DOE tools
Fishbone diagrams
Handoff maps
KPOVs
Load charts
MSA tools
Multi-Cycle analyses
Multi-Vari studies
Murphy s analyses
Normality tests
OEE
Pareto charts
Poka Yoke
Process FMEA
Process variables (I/O) maps
Project charter
Pull systems & Kanban
Rapid changeover
Regression
SIPOC
Spaghetti maps
SPC
Swimlane maps
Time tools
Whether you re a Green Belt, Black Belt, Master, Project Champion, Sponsor, Deployment Leader, or consultant, this book will help you use Lean Sigma to solve far more problems, far more rapidly, and far more effectively.
Dr. Ian Wedgwood, Executive Director of Sigma Breakthrough Technologies, has more than ten years of experience using, deploying, training, and consulting on Six Sigma and Lean Sigma. He has led and facilitated deployments in industries ranging from electronics and medical devices to chemicals and health care, and has trained and mentored numerous executives, champions, and belts. He holds a Ph.D. and First-Class Honors degree in Applied Mathematics from Scotland s St. Andrew s University.
Chapter 1 Introduction 1
PART I PROJECT ROADMAPS TO SOLVE BUSINESS PROBLEMS
Chapter 2 Define Tools Roadmap Applied to the Beginning of All Projects 13
Chapter 3 Global Process Problems 23
A: On-Time Delivery Issues 23
B: Capacity of Process Is Too Low 27
C: RTY, Defects, Accuracy, Quality, Scrap, and Rework Issues 29
D: % Uptime Is Too Low 33
E: Pace of Process Too Slow 36
F: Process Has Enough Capacity, But Fails Intermittently 38
G: Process Has Enough Capacity, But Process Lead Time Is Too Long 41
H: Individual Steps Meet Takt, Global Process Does Not 44
I: Demand from the Customer Is Too Variable 47
J: Too Many Entity Types (Products) 51
K: High Schedule Variation 54
L: Measurement System Broken 60
M: Performance Characteristic Not Good Enough 63
N: Planned Maintenance Takes Too Long 64
O: Setup/Changeover Takes Too Long 65
P: Too Much Unplanned Maintenance 68
Q: Process Can t Make Product at All 72
R: Resource Usage Is Too High (Headcount Reduction) 75
S: Inventory Is Too High 78
T: Waste/Process Loss Too High 82
U: High Forecast Variation 85
V: Not Enough Sales 89
W: Backlog of Orders Is Too High 91
X: Payments Made to Suppliers Not Optimized 93
Y: Accounts Receivable Are Too High 95
Chapter 4 Individual Step Process Problems 99
Chapter 5 Control Tools Used at the End of All Projects 107
PART II ROADMAPS TO FIND PROJECTS WHERE NO OBVIOUS CANDIDATES EXIST
Chapter 6 Discovery Tools Applied to Identify Projects 115
PART III ROADMAPS TO GUIDE IN THE PRACTICAL APPLICATION OF EACH LEAN SIGMA TOOL
Chapter 7 Tools 119
01: 5 Whys 119
02: 5S 122
03: Affinity 130
04: ANOVA 133
05: Box Plot 141
06: Capability Attribute 143
07: Capability Continuous 146
08: Cause & Effect (C&E) Matrix 153
09: Chi-Square 157
10: Control Charts 163
11: Critical Path Analysis 171
12: Customer Interviewing 174
13: Customer Requirements Tree 183
14: Customer Surveys 186
15: Demand Profiling 193
16: Demand Segmentation 196
17: DOE Introduction 202
18: DOE Screening 213
19: DOE Characterizing 222
20: DOE Optimizing 237
21: Fishbone Diagram 249
22: Handoff Map 253
23: KPOVs and Data 257
24: Load Chart 268
25: MSA Validity 272
26: MSA Attribute 276
27: MSA Continuous 284
28: Multi-Cycle Analysis 294
29: Multi-Vari Studies 300
30: Murphy s Analysis 306
31: Normality Test 308
32: Overall Equipment Effectiveness (OEE) 311
33: Pareto Chart 318
34: Poka Yoke (Mistake Proofing) 321
35: Process FMEA 325
36: Process Variables (Input/Output) Map 330
37: Project Charter 333
38: Pull Systems and Kanban 342
39: Rapid Changeover (SMED) 354
40: Regression 362
41: SIPOC 372
42: Spaghetti (Physical Process) Map 376
43: Statistical Process Control (SPC) 380
44: Swimlane Map 384
45: Test of Equal Variance 389
46: Time Global Process Cycle Time 392
47: Time Individual Step Cycle Time 395
48: Time Process Lead Time 398
49: Time Replenishment Time 401
50: Time Takt Time 404
51: Total Productive Maintenance 408
52: t-Test 1-Sample 411
53: t-Test 2-Sample 416
54: t-Test Paired 422
55: Value Stream Map 423